Cured in place liner system and installation methods

ABSTRACT

A cured in place liner system and associated connections and methods are disclosed. The cured in place pipe system forms a completely rehabilitated, stand-alone, fluid-tight flow path between upstream and downstream portions of an existing pipe system. The rehabilitated flow path is stand-alone in that the liner system does not rely on structure of the portion of the pipe system through which the liner system is installed to define the fluid-tight flow path. The flow path between upstream and downstream portions of the liner system is defined by and made fluid-tight solely by components of the rehabilitation system such as cured in place liners and couplers. The portion of the pipe system through which the rehabilitation system is installed merely provides a path (e.g., through the ground) through which the cured in place liner system can be inserted. After the cured in place liner system is installed, the liner system forms a fluid-tight flow path between an upstream portion of the pipe system and a downstream portion of the pipe system. Various types of connections may be used. In addition, various types of methods may be used in forming the connections, such as using a mold to cure connecting sections of the cured in place liners in desired configurations (e.g., having a generally circular outer profile) for forming connections with the liners.

FIELD OF THE INVENTION

The present disclosure generally relates to pipe rehabilitation. Inparticular, the present disclosure relates to pipe rehabilitation usinga cured in place liner system.

BACKGROUND

This invention relates to a cured in place liner system and methods forinternally lining an existing pipe with a cured in place liner system. Avariety of circumstances exist in which it is desirable to line apipeline. For instance, in the municipal area, it may be necessary toline a water distribution pipes to form a rehabilitated flow path. Asimilar need exists in other industries, such as in the chemicalpipeline industries. Conventional pipe lining operations require use ofcomponents of the existing pipe system to form the rehabilitated flowpath. For example, the liner may depend on a seal with the existing pipeto form a rehabilitated fluid-tight flow path. It is desirable toprovide improved systems and methods to rehabilitate a pipeline.

SUMMARY

In one aspect, the present invention includes a method for installing aliner impregnated with a curable resin in a previously installed hostpipe. The method includes positioning a mold which is separate from thepipe at an end of the pipe. The liner is positioned in the pipe so aconnecting section of the liner extends into the mold. The liner iscured whereby the mold causes the connecting section to cure in apredetermined desired configuration for forming a connection with theliner. The mold is removed from the liner.

In another aspect, the present invention includes a rehabilitated pipesystem including an existing pipe system. The rehabilitated pipe systemincludes a cured in place pipe system comprising separately formedlengths of resin cured liner installed in the existing pipe system. Theseparately formed lengths of resin cured liner are adjacent to eachother and sealed to each other so that the cured in place pipe system isstand alone having no fluid communication with the existing pipe system.

In another aspect, the present invention includes a method of installinga pipe rehabilitation system in a portion of a previously installed hostpipe system. The method includes installing a first length of cured inplace liner into the previously installed host pipe system andinstalling a second length of cured in place liner into the previouslyinstalled host pipe system. The first and second lengths of cured inplace liner are in generally end to end relation. The method alsoincludes forming a fluid tight connection joint between the first andsecond lengths of installed lengths of cured in place liner that isindependent of the previously installed host pipe system.

Other objects and features of the present invention will be in partapparent and in part pointed out hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary section of a rehabilitated pipe system includinga cured in place liner system;

FIG. 2 is an enlarged fragmentary section of a cured in place liner toexisting pipe joint of a first embodiment;

FIG. 3 is a fragmentary section of a cured in place liner to cured inplace liner joint of a first embodiment;

FIGS. 4A-4D are fragmentary sections illustrating a sequence of forminga cured in place liner having an end portion as illustrated in FIGS. 2and 3;

FIG. 5 is a fragmentary section of a cured in place liner to existingpipe joint of a second embodiment;

FIG. 6 is a fragmentary section of a cured in place liner to cured inplace liner joint of a second embodiment;

FIG. 7A-7D are fragmentary sections illustrating a sequence of forming acured in place liner having an end portion as illustrated in FIGS. 5 and6;

FIG. 8 is a fragmentary section of a cured in place liner to existingpipe joint of a third embodiment;

FIG. 9 is a fragmentary section of a cured in place liner to existingpipe joint which is similar to the embodiment shown in FIG. 8 butincluding a reinforcing member;

FIG. 10 is a fragmentary section of a cured in place liner to cured inplace liner joint of a third embodiment;

FIG. 11 is a fragmentary section of a cured in place liner to cured inplace liner joint which is similar to the embodiment shown in FIG. 10but including reinforcing members;

FIGS. 12A-12D are fragmentary sections illustrating a sequence offorming a cured in place liner having an end portion as illustrated inFIGS. 8 and 9;

FIG. 13 is a fragmentary section of a cured in place liner to existingpipe joint of a fourth embodiment similar to the joint illustrated inFIG. 5 but including a reinforcing member;

FIG. 14 is a fragmentary section of a cured in place liner to cured inplace liner joint of a fourth embodiment similar to the jointillustrated in FIG. 6 but including reinforcing members;

FIG. 15 is a fragmentary section of a cured in place liner to cured inplace liner joint of a fifth embodiment including a bridge member;

FIG. 16 is a fragmentary section of a cured in place liner to cured inplace liner joint of a sixth embodiment;

FIG. 17 is a fragmentary section of a cured in place liner to cured inplace liner joint of a seventh embodiment; and

FIG. 18A-18B are fragmentary sections illustrating a sequence of forminga cured in place liner having connecting sections at opposite ends ofthe liner using two molds.

Corresponding reference characters indicate corresponding partsthroughout the drawings.

DETAILED DESCRIPTION

In the municipal area, many water mains were constructed years ago andthe wall structures are now badly eroded or collapsing. Damaged waterpipes present a serious problem because they may lead to contaminationof drinking water. In order to repair these water mains or other suchconduits, it has been proposed to install a liner within the water mainsto provide a new water-impervious wall to the system. There are a widevariety of different methods available in the art for inserting linerswithin existing conduits. These lining methods may include eversion orpull-in of a resin impregnated liner and curing the liner after it ispositioned within the pipeline.

It is desirable to provide a cured in place pipe rehabilitation systemextending through a portion of an existing pipe system to form acompletely rehabilitated, stand-alone, fluid-tight flow path betweenupstream and downstream portions of the existing pipe system. Therehabilitated flow path is stand-alone in that the rehabilitation systemdoes not rely on structure of the portion of the pipe system throughwhich the rehabilitation system is installed to define the fluid-tightflow path. The flow path between the portions of the pipe systemupstream and downstream of the rehabilitation system is defined by andmade fluid-tight solely by components of the rehabilitation system suchas cured in place liners and couplers, as described in further detailbelow. The portion of the pipe system through which the rehabilitationsystem is installed merely provides a path (e.g., through the ground)through which the cured in placer liner system can be inserted. Afterthe cured in place liner system is installed, the liner system forms afluid-tight flow path between an upstream portion of the pipe system anda downstream portion of the pipe system. It will be apparent to those ofordinary skill in the art that the rehabilitation system may occupy allor only a part of a pipe system. Other parts of the pipe system may evenbe lined, but with liners that rely on existing pipe to form joints.

Referring now to the drawings and in particular to FIG. 1, arehabilitated pipe system is designated generally at 10. A piperehabilitation system generally comprises a cured in place liner system,generally designated 12, and connecting joints, generally designated at14, 24, 114, 124. The cured in place liner system 12 is installed in aportion of an existing pipe system, usually comprising multiple lengthsof pipe 20. The cured in place liner system 12 is installed along andwithin the lengths of host pipe 20 making up the portion of the pipesystem to be rehabilitated. The cured in place liner system 12 comprisesat least one cured in place liner 22, 122. The liner system 12 maycomprise an assembly of several cured in place liners 22, 122, dependingupon the length of the portion of the pipe system to be rehabilitated.Only two lines are shown, but any number of liners may be used to form acured in place liner system. The cured in place liners 22, 122 aregenerally flexible and comprise at least a layer of resin impregnablematerial (e.g., polyester felt) and a layer of impermeable material(e.g., a plastic film). Various constructions of cured in place liners22, 122 are known in the art, and such constructions may be used withoutdeparting from the scope of the present invention. The liners 22, 122may be inserted by, for example, eversion or pull-in into the existinghost pipes 20 or other methods known in the art. Various configurationsand methods for coupling the liners 22, 122 in fluid communication willbe discussed in more detail below.

The connecting joints 14, 114 connect the cured in place liner system 12in fluid communication with the existing pipe system upstream anddownstream of the portion of the pipe system to be rehabilitated.Connecting joints such as joints 14, 114 which connect upstream anddownstream ends of the cured in place liner system 12 with the existingpipe system may be referred to as terminal joints. Intermediateconnecting joints 24, 124 are used to connect adjacent cured in placeliners 22, 122 in fluid communication with each other. The connectingjoints 14, 24, 114, 124 each form a fluid-tight connection. Theconnecting joints 14, 114 of FIG. 1 include a coupler 30, 130 and acoupling section 22A, 122A of a respective liner 22, 122, and mayinclude a pipe segment 32, 132 for facilitating connection to theexisting pipeline. For example, as illustrated in FIG. 1, the pipesegments 32, 132 may be flanged to correspond to a flanged termination(not shown) of the existing pipeline to facilitate connection to theexisting pipeline (e.g., by securing the flanges via bolts).Alternatively, the connecting joint 14, 114 may comprise a couplersimilar to those indicated 30 or 130 that connect the cured in placeliner system 12 directly to the existing pipe system without the use ofa pipe segment 32, 132 (not shown in FIG. 1). Other types of connectingjoints are within the scope of the present invention. Various types ofconnecting joints will be described in more detail below. Examplecouplers that may be used are described in U.S. Pat. Nos. 5,941,576 and6,293,556, which are herein incorporated by reference in theirentireties. Couplers which may be used include those sold by TotalPiping Solutions, Inc. of Olean, N.Y. under the trade name HYMAX andthose sold by EBAA Iron, Inc. of Eastland, Tex. under the trade nameMEGALUG.

FIG. 2 shows the connecting joint 14 of FIG. 1 in more detail andillustrates a first embodiment of a connection between the existing pipesystem and an end of the cured in place liner system 12. As explainedabove, the connecting joint 14 comprises the coupler 30, the linercoupling section 22A, and the pipe segment 32, but the pipe segment 32may be omitted and the coupler and liner coupling section be used toconnect the cured in place liner system directly in fluid communicationwith the existing pipe system. The joint to a pipe of the existing pipesystem can be the same as the connection of the liner coupling section22A to the pipe segment 32 illustrated in FIG. 2. A cured in place liner22 of the liner system 12 is installed in a pipe 20 of the existing pipesystem. A portion 22B of the cured in place liner 22 is inside the pipe20 and conformed to an inner surface of the pipe. An end portion of thecured in place liner 22 forming the liner coupling section 22A extendsout of the pipe 20. The liner coupling section 22A has an increasedthickness relative to the portion 22B inside the pipe. For example, theportion 22B inside the pipe may have a thickness of about 3/16 inch (4.8mm). The portion 22A may have a thickness of about ⅜ inch (9.5 mm). Inother words, the portion 22A may be about two times thicker than theportion 22B. The thicknesses may be other than disclosed herein withoutdeparting from the scope of the present invention. The increasedthickness provides greater resistance against buckling, which may becaused by force applied to the outside surface of the liner couplingsection 22A by tightening or clamping of the coupler 30 on the linercoupling section. The increased thickness also provides the linercoupling section 22A with an increased outside diameter. The portion 22Binside the pipe 20 has an outside diameter approximately the same as theinside diameter of the pipe (e.g., about 8 inches (20 cm)). If the linercoupling section 22A were not increased in diameter, the liner couplingsection may have the same outside diameter as the portion 22B inside thepipe. Commonly available and/or less expensive couplers 30 may not beconstructed having a diameter corresponding to that of the insidediameter of the pipe 20. The increased diameter of the liner couplingsection 22A is preferably about the same as the outside diameter of thepipe 20 (e.g., about 8.5 inches (22 cm)). Commonly available and/or lessexpensive couplers are likely constructed with diameters correspondingto the outside diameter of the pipe 20 and thus the outside diameter ofthe thickened liner coupling section 22A of the liner 22. Anotheradvantage of the increased thickness of the liner coupling section 22Ais that a coupler 30 having a constant diameter may be used. The coupler30 forms a fluid-tight connection. The cured in placer liner 22 maycontain reinforcement (e.g., carbon, glass, steel) that increases itsbuckling strength. The cured in place liner 22 is shown in abuttingrelationship with the pipe segment 32 in FIG. 2, but may be spaced fromthe pipe segment (as is the case with other types of terminalconnections).

FIG. 3 shows the connecting joint 24 of FIG. 1 in more detail andillustrates a first embodiment of a connection between adjacent cured inplace liners 22 of the liner system 12. The liners 22 are showninstalled in respective pipes 20 of the existing pipe system. The linershave portions 22B inside the pipes 20 and liner coupling sections 22A attheir ends with increased thickness, similar to the liner couplingsection 22A shown in FIG. 2. As explained above with reference to FIG.2, the portions 22B inside respective pipes 20 may have a thickness ofabout 3/16 inch (4.8 mm), and the coupling sections 22A may have athickness of about ⅜ inch (9.5 mm). In other words, the couplingsections 22A may be about two times thicker than the portions 22B. Thethicknesses may be other than disclosed herein without departing fromthe scope of the present invention. A coupler 34 fluidly couples theliners 22. The thickened liner coupling sections 22A may have an outsidediameter approximately the same as the outside diameter of the pipes 20through which the liners are installed (e.g., about 8.5 inches (22 cm)).The thickened liner coupling sections 22A provide similar advantages asdescribed above. For example, the liner coupling sections 22A haveincreased resistance against buckling. The connecting joint 24 forms afluid-tight flow path between the liners. The cured in placer liners 22may contain reinforcement (e.g., carbon, glass, steel) that increasestheir buckling strength. The coupler 34 may have a similar constructionas the coupler 30 illustrated in FIG. 2. The cured in place liners 22are shown in abutting relationship in FIG. 3, but may be spaced fromeach other (as is the case with other types of intermediateconnections).

Figures. 4A-4D illustrate in sequence a method that may be used to forma cured in place liner 22 having a thickened liner coupling section 22Alike those shown in FIGS. 2 and 3. Referring to FIG. 4A, a resinimpregnated tubular liner sleeve 40 is positioned in a tubular mold 46.The liner sleeve 40 may comprise the same material as the liner 22 or adifferent material. The resin impregnated liner sleeve 40 may bepartially cured so that it has sufficient rigidity to maintain a tubularshape inside the mold 46. The mold 46 is separate and distinct from anyof the pipes 20. The mold 46 is positioned adjacent to and in alignmentwith an existing pipe 20 into which a liner 22 will be inserted. Asshown in sequence in FIGS. 4A-4C, the liner 22 is illustrated as beinginserted into the pipe 22 by eversion (but may be inserted by othermethods, including pull-in). The everting liner 22 advances within thepipe 20 until a terminal portion 22C of the liner 22 (FIG. 4C) extendsout of the pipe 20 and into or through the sleeve 40 in the mold 46. Theliner 22 may be everted using fluid pressure within the liner. The fluidpressure causes the liner 22 to conform to an inside surface 20A of thepipe 20 and conform to an inside surface 40A of the liner sleeve. Theliner 20 and the liner sleeve 40 are cured (e.g., simultaneously) whenin a configuration such as shown in FIG. 4C so that the liner sleevecures on the outside of the liner and forms an integral part of theliner. In other words, the sleeve 40 bonds to the liner 20 to form thecoupling section 22A. As shown in FIG. 4D, the terminal portion 22C ofthe liner is then removed (e.g., cut away), leaving the liner with aliner coupling section 22A extending out of the pipe having an increasedthickness. The mold 46 may have an inside diameter approximately thesame as the outside diameter of the existing pipe 20 so that the curedliner sleeve 40 has a corresponding outside diameter. The mold 46 mayhave other inside diameters (e.g., corresponding to an inside diameterof a desired coupler) without departing from the scope of the presentinvention. The cured liner coupling section 22A as illustrated in FIG.4D is ready to have a coupler 30, 34 mounted thereon for connecting theliner in fluid communication with either the existing pipe system (e.g.,FIG. 2) or another liner 22 (e.g., FIG. 3).

Various types of molds 46 may be used. The mold 46 may be a tubular moldwith a continuous diameter, in which case the mold could be removed fromthe liner coupling section 22A by sliding it longitudinally off of theend portion. Alternatively, the mold 46 may be a clamshell or otherconstruction that enables a “quick release” and perhaps more convenientremoval from the liner coupling section 22A. The mold 46 may be madefrom various suitable materials such as a plastic or metal material.Lubrication may be applied to the inside surface of the mold 46 tofacilitate removal from the cured liner sleeve 40. The mold 46facilitates curing of the coupling section 22A in a predetermineddesired configuration. For example, the mold 46 may have a generallycircular inner profile for curing the coupling section 22A to have agenerally circular outer profile. This enhances conformance of thecoupling section 22A to the coupler 30, 34, which enhances the fluidseal between the coupling section and the coupler.

FIG. 5 shows the connecting joint 114 of FIG. 1 (in mirror image) inmore detail. As explained above, the connecting joint 114 comprises thecoupler 130, the liner coupling section 122A, and the pipe segment 132,but the pipe segment may be omitted and the coupler and liner couplingsection be used to connect the cured in place liner system 12 directlyin fluid communication with the existing pipe system. The connection maylook the same as the connection of the liner coupling section to thepipe segment illustrated in FIG. 5. A cured in place liner 122 of theliner system 12 is shown installed in a pipe 20 of the existing pipesystem. The connection of this embodiment is different than theconnection shown in FIG. 2 in that the liner coupling section 122A ofthe liner 122 is not thickened and the coupler 130 is a reducingcoupler. The liner coupling section 122A has approximately the samethickness as the portion of the liner 122B inside the pipe 20. The endportion 122A also has approximately the same outside diameter as theportion 122B inside the pipe. The reducing coupler 130 has first andsecond ends 130A, 130B constructed with different diameters, thediameter of the first end 130A corresponding to the diameter of the pipesegment 132, and the diameter of the second end 130B corresponding tothe diameter of the liner coupling section 122A. The coupler 130 forms afluid-tight connection.

FIG. 6 shows the connecting joint 124 of FIG. 1 in more detail andillustrates a second embodiment of a connection between adjacent curedin place liners 122 of the liner system 12. The liners 122 are showninstalled in respective pipes 20 of the existing pipe system. Theconnection of this embodiment is different than the connection shown inFIG. 3 in that the liner coupling sections 122A of the liners haveapproximately the same thickness as the portions of the liners 122Binside the pipes 20. The liner coupling sections 122A also haveapproximately the same outside diameter as the respective portions 122Binside the pipes 20. A constant diameter coupler 134 may be used becausethe outside diameter of the liner coupling sections 122A isapproximately the same. The cured in placer liners 122 may containreinforcement (e.g., carbon, glass, steel) that increases its bucklingstrength without significantly increasing the thickness or outsidediameter of the liner. The connecting joint 124 forms a fluid-tight flowpath between the liners 122.

FIGS. 7A-7D illustrate in sequence a method that may be used to form acured in place liner 122 having a liner coupling section 122A like thoseshown in FIGS. 5 and 6. Referring to FIG. 7A, a mold 146 is positionedadjacent and in alignment with an existing pipe 20 through which a liner122 will be inserted. The mold 146 may have a construction similar tothe construction of the mold 46 described above. In this embodiment, theinside diameter of the mold 146 is approximately the same as the insidediameter of the pipe 20. As shown in sequence in FIGS. 7A-7C, the liner122 is illustrated as being inserted into the pipe 20 by eversion (butmay be inserted by other methods, including pull-in). The everting liner122 advances within the pipe 20 until a terminal portion 122C of theliner 122 (FIG. 7C) extends out of the pipe and into or through the mold146. The liner 122 may be everted using fluid pressure within the liner.The fluid pressure causes the liner 122 to conform to an inside surface20A of the pipe 20 and conform to an inside surface 146A of the mold146. The liner 122 is cured when in a configuration such as shown inFIG. 7C so that the segment of the liner extending out of the pipe cureshaving a diameter approximately the same as the inside diameter of themold. As shown in FIG. 7D, the terminal portion 122C is then removed(e.g., cut away), leaving the liner with a liner coupling section 122Aextending out of the pipe 20 having an outside diameter approximatelythe same as the inside diameter of the pipe. In other words, the endportion 122A and the portion of the liner 122B inside the pipe 20 havegenerally the same outside diameter. As explained above with respect tocoupling sections 22A, the mold 146 facilitates curing of the couplingsections 122A in a predetermined desired configuration (e.g., having agenerally circular outer profile). The cured end portion 122A asillustrated in FIG. 7D is ready to have a coupler 130, 134 mountedthereon for connecting the liner 122 in fluid communication with eitherthe existing pipe system (e.g., FIG. 5) or another liner 122 (e.g., FIG.6).

FIG. 8 shows a third embodiment of a connecting joint 214 between theexisting pipe system and an end of the cured in place liner system 12.As with the prior embodiments, the connecting joint 214 comprises acoupler 230 and a liner coupling section 222A. In this embodiment, theliner coupling section 222A has an increased diameter but substantiallyconstant thickness. The outside diameter of the end portion 222A isapproximately the same as the outside diameter of the pipe 20 so that aconstant diameter coupler 230 may be used.

FIG. 9 shows a modified version 214′ of the connecting joint 214. Thejoint 214′ is similar to the joint 214 in that it is a terminalconnection. The connecting joint 214′ includes a coupler 230′, and theliner 222′ includes a coupling section 222A′. In this modified version,a reinforcing member 250 is provided inside the liner 222′ to underliethe liner coupling section 222A′. The reinforcing member 250 may betubular and have an outside diameter generally corresponding to theinside diameter of the liner coupling section 222A′. The reinforcingmember 250 can be inserted in the liner coupling section 222A′ before orafter cure of the liner 222′ and could be adhered to the liner using anepoxy, for example. The reinforcing member 250 may comprise carbon,glass, steel and/or other reinforcing material. In one embodiment, thereinforcing member 250 comprises resin impregnated material which iscured and bonds to the liner 222′. Alternatively or in addition, thereinforcing member 250 may include a substance such as an epoxy appliedto the inside or outside surface of the end portion. The reinforcingmember 250 provides the liner coupling section 222A′ with greaterresistance against buckling. Such reinforcing members may be used inother embodiments of terminal connections (e.g., the embodiment shown inFIG. 2) without departing from the scope of the present invention.

FIG. 10 shows a third embodiment of a connecting joint 224 betweenadjacent cured in place liners 222 of the cured in place liner system12. As in the prior embodiments, this joint 224 includes a coupler 234and liner coupler sections 222A. The liner coupling sections 222A haveincreased diameters but substantially constant thicknesses. The outsidediameters of the liner coupling sections 222A may be approximately thesame as the outside diameters of the pipes 20. Desirably, the increasedoutside diameters of the liner coupling sections 222A are approximatelythe same so that a constant diameter coupler 234 may be used.

FIG. 11 shows a modified version 224′ of the connecting joint 224. Thejoint 224′ is similar to the joint 224 in that it is an intermediateconnection. The connecting joint 224′ includes a coupler 234′, and theliners 222′ each include a coupling section 222A′. In this modifiedversion, a reinforcing member 250 is provided inside each liner 222′ tounderlie the liner coupling sections 222A′. The reinforcing members 250may be tubular and have an outside diameter generally corresponding tothe inside diameter of the liner coupling sections 222A′. Thereinforcing member 250 can be inserted in the liner coupling sections222A′ before or after cure of the liners 222′ and could be adhered tothe liner using an epoxy, for example. The reinforcing members 250 mayhave a construction as described above with respect to FIG. 9. Thereinforcing members 250 provides the liner coupling sections 222A′ withgreater resistance against buckling. Such reinforcing members may beused in other embodiments of intermediate connections (e.g., theembodiment shown in FIG. 3) without departing from the scope of thepresent invention.

FIGS. 12A-12D illustrate in sequence a method that may be used to form acured in place liner 222 having an end portion 222A like those shown inFIGS. 8 and 10. Referring to FIG. 12A, a mold 246 is positioned adjacentand in alignment with an existing pipe 20 through which a liner 222 willbe inserted. In this embodiment, the inside diameter of the mold 246 isapproximately the same as the outside diameter of the pipe 20. As shownin sequence in FIGS. 12A-12C, the liner 222 is illustrated as beinginserted into the pipe 20 by eversion (but may be inserted by othermethods, including pull-in). The everting liner 222 advances within thepipe 20 until a terminal portion 222C of the liner extends out of thepipe and into or through the mold 246. The liner 222 may be evertedusing fluid pressure within the liner. The fluid pressure causes theliner 222 to conform to an inside surface 20A of the pipe 20 and conformto an inside surface 246A of the mold 246. As with the molds describedabove, the mold 246 facilitates curing of the coupling section 222A in apredetermined desired configuration (e.g., having a generally circularouter profile). The liner 222 is cured when in a configuration such asshown in FIG. 12C so that the segment of the liner extending out of thepipe 20 cures having a diameter approximately the same as the insidediameter of the mold 246. As shown in FIG. 12D, the terminal portion222C of the liner is then removed (e.g., cut away), leaving the linerwith a liner coupling section 222A extending out of the pipe having adiameter approximately the same as the outside diameter of the pipe. Thecured end portion as illustrated in FIG. 12D forms a liner couplingsection 222A ready to have a coupler 230, 234 mounted thereon forconnecting the liner 222 in fluid communication with either the existingpipe system or another liner 222 such as shown in FIGS. 8 and 10,respectively. If desired, reinforcing members 250 may be inserted intothe liner to form coupling sections 222A′ for making connections such asthose shown in FIGS. 9 and 11.

FIG. 13 shows a fourth embodiment of a connecting joint 314 between theexisting pipe system and an end of the cured in place liner system 12.This embodiment is similar to the embodiment shown in FIG. 5. A reducingcoupler 330 is used to couple the liner coupling section 322A which hasa smaller outside diameter than the pipe 20. In this embodiment, theliner coupling section 322A includes a reinforcing member 350 isinserted inside the liner coupling section 322A. The reinforcing member350 may be similar to the reinforcing members 250 described above withrespect to FIGS. 9 and 11. The reinforcing member 350 provides the linercoupling section 322A with greater resistance against buckling.

FIG. 14 illustrates a fourth embodiment of a connecting joint 324between adjacent cured in place liners 322 of the cured in place linersystem 12. This embodiment is similar to the one shown in FIG. 6 butincludes two reinforcing members 350 inserted inside respective endportions 322B. The reinforcing members 350 may be similar to thosedescribed above with respect to FIGS. 9 and 11. For example, acontinuous reinforcing member that spans between the liner couplingsections of each liner may be used instead of two separate reinforcingmembers 350, as illustrated. The reinforcing members provide the linercoupling sections 322A with greater resistance against buckling.

FIG. 15 illustrates a fifth embodiment of a connecting joint 424 betweenadjacent cured in place liners 422 of the cured in place liner system12. In this embodiment, the connecting joint 424 comprises first andsecond couplers 460, 462 and a bridge member 470 (or “spool”). The firstand second couplers 460, 462 are illustrated as constant diametercouplers but one or both may comprise reducing couplers. The couplers460, 462 form a fluid-tight connection with the bridge member 470 byconnection of flanges 460A, 462A on the couplers to correspondingflanges 470A, 470B on the bridge member 470 (e.g., using bolts 480).Alternatively, the bridge member 470 and couplers 460, 462 may not haveflanges 460A, 462A, in which case couplers may overlap and form aliquid-tight seal about an outer surface of the bridge member 470 asthey do with the cured in place liners 422. The illustrated linercoupling sections 422A have increased thicknesses, like the embodimentsshown in FIGS. 2 and 3, but other types of liner coupling sections maybe used, such as those shown in FIGS. 5, 6, 8-11, 13, and 14. Althoughthe bridge member 470 is illustrated in FIG. 15 as part of anintermediate connection, such a bridge member may also be used as partof a terminal connection (e.g. in the embodiment of FIG. 2). The bridgemember 470 facilitates installation of the cured in place liner system12 because the liner coupling sections 422A may be spaced relatively farfrom each other. Thus, the installation of the cured in place liners 422(including insertion and cure) can be carried out without closeprecision regarding positioning the liner coupling sections 422A of theliners proximate each other. The bridge member 470 can be selected witha suitable length to bridge the gap between the liner coupling sections422A such that the couplers 460, 462 are positioned properly for sealingabout the liner coupling sections. The connecting joint 424 forms afluid-tight flow path between the liners 422. Bridge members such as thebridge member 470 may be used in any of the connections disclosed hereinor connections having other configurations without departing from thescope of the scope of the present invention.

FIG. 16 illustrates a sixth embodiment of a connecting joint 524 betweenadjacent cured in place liners 522 of the cured in place liner system12. In this embodiment, the liners 522 are installed such that the endportions 522A of the liners (defining liner coupling sections) overlapeach other. The liners 522 are cured in this condition so that theliners form a fluid-tight seal between the liner coupling sections 522A.Alternatively or in addition, a coupler 534 may be used to couple andform a fluid-tight seal between the liner coupling sections 522A. Asanother alternative, a band (not shown) may be disposed and tightenedabout the overlapping liner coupling sections 522A to seal the linercouplings sections together without forming a seal with one of the pipes20. Other embodiments in which the end portions of the liners 522overlap may be used.

FIG. 17 illustrates a seventh embodiment of a connecting joint 624between adjacent cured in place liners 622 of the cured in place linersystem 12. In this embodiment, the connecting joint 624 comprisescouplers which are flange fittings 690 inserted inside the linercoupling sections 622A. A seal is formed between each flange fitting 690and its respective liner 622. For example, bands (not shown) may bedisposed and tightened about the outside surfaces of the liner couplingsections 622A to clamp the liners on the flange fittings. Alternativelyor in addition, an adhesive may be applied to the inside of the linercoupling section 622A or outside of the flange fitting 690 to make aseal. Flanges 690A on the flange fittings 690 are constructed to besecured together (e.g., by bolts 692) to form a fluid tight seal betweenthe flange fittings. Flange fittings such as the flange fittings 690 mayalso be used to form terminal connections.

In some embodiments, a cured in place liner may be installed using twomolds. FIGS. 18A-18B illustrate in sequence a method in which two molds746A, 746B are used to install a liner 722. As shown in FIG. 18A, afirst mold 746A is positioned at one end of the pipe 20, and a secondmold 746B is positioned at an opposite end of the pipe. In use, theliner 722 is positioned in the pipe 20 so the connecting sections 722Aof the liner extend out of the pipe into the molds 746A, 746B. The liner722 may be installed by inserting it through the first mold 746A,through the pipe 20, and then into or through the second mold 746B. Inthe illustrated embodiment, the liner 722 is installed by eversion, butthe liner may be inserted by pulling it into position without departingfrom the scope of the present invention. Fluid pressure in the liner 722causes outer surfaces of the connecting sections 722A to conform toinner surfaces of the molds 746A, 746B. To complete the installation,the liner 722 is cured, the ends of the liner are cut to length, and themolds 746A, 746B are removed, as shown in FIG. 18B. The connectingsections 722A may then be connected to other liners or to another pipeof the previously installed pipe system.

The molds illustrated in FIG. 18 are similar to the mold 146 illustratedin FIGS. 7A-7D and are used to form liner connecting sections similar tothe connecting section 122A shown in FIGS. 5, 6, and 7D. Other types ofmolds may be used in this same fashion, with one mold positioned at afirst end of the pipe and another mold positioned at the opposite end ofthe pipe. For example, any of the molds 46, 146, 246 described above maybe used at either end of the pipe 20 to form a respective linerconnecting section such as illustrated in FIGS. 4A-4D, 7A-7D, or12A-12D.

The various connecting joints described above may be formed atpreexisting connection points of the existing pipe system, or be formedat any point along the existing pipe system at which it may be desirableto cut the existing pipe system (e.g., at regular intervalscorresponding approximately to lengths of cured in place liners to beinstalled). For example, the pipes 20 and 32 shown in FIG. 2, and thepipes 20 shown in FIG. 3, respectively, could have been part of the samepipe before a segment was removed and the cured in place liners and thecouplers were installed.

The methods described above in which a mold is used may be carried outwithout the use of a mold. For example, the liner sleeve may be appliedby hand about the end portion of the liner (before or after the liner iscured) without use of the mold. The mold serves to restrict theexpansion of the liner and to cause the end portion of the liner to curein a desirable state (e.g., circular) for facilitating formation of acontinuous seal around the outside surface of the liner.

It is understood embodiments of intermediate connecting joints disclosedherein require no fluid communication with the previously installed(“existing”) pipe system through which the cured in place pipe system isinstalled. The previously installed pipe system essentially serves as aform for shaping the cured in place pipe system. Once formed, the curedin place pipe system may stand alone with respect to the previouslyinstalled pipe system. For example, the intermediate connecting jointsillustrated in FIGS. 1, 3, 6, 10, 11, 14, 15, and 17 require noconnection or support from the previously installed pipe system. Thecouplers, bridge members, and other components which form theconnections between the cured in place liners do not engage or contactpipes 20 of the previously installed pipe system. Moreover, theintermediate connecting joint components form a fluid-tight flow pathacross the joints themselves, without use of structure of pipes 20 ofthe previously installed pipeline system. In comparison, theintermediate connection illustrated in FIG. 16 uses a portion of thepreviously installed pipe system to form the connection. Morespecifically, the coupler 534 is partially mounted on the pipe. In theother disclosed embodiments of intermediate connections, for example,the couplers and other connection structure forming the intermediateconnections are mounted solely on the cured in place liners.

In use, after a rehabilitation system of the type described herein hasbeen installed, the fluid flow through the existing pipe system can berestored. The fluid flows from the upstream portion of the previouslyinstalled pipe system through the rehabilitation system to thedownstream portion of the previously installed pipe system. Therehabilitation system defines a stand-alone fluid-tight flow path thatis independent from the portion of the previously installed pipe systemthrough which the rehabilitation system is installed.

Having described the invention in detail, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

As various changes could be made in the above constructions and methodswithout departing from the scope of the invention, it is intended thatall matter contained in the above description and shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

1-20. (canceled)
 21. A rehabilitated host pipe comprising: an existinghost pipe; a sleeve positioned at an end of the pipe; and a liner liningan inside surface of the pipe and extending into the sleeve, the linerbeing bonded to the sleeve to form a coupling section extending out ofthe end of the pipe, the coupling section being configured to have acoupler mounted thereon for connecting the liner in fluid communicationwith another pipe.
 22. A rehabilitated host pipe as set forth in claim21 wherein the liner and sleeve comprise the same material.
 23. Arehabilitated host pipe as set forth in claim 21 wherein the sleeve andthe pipe have interior lumens defining inner diameters of substantiallyequal size and being substantially aligned with one another.
 24. Arehabilitated host pipe as set forth in claim 21 wherein the linerconforms to an inside surface of the host pipe.
 25. A rehabilitated hostpipe as set forth in claim 21 wherein the liner conforms to an insidesurface of the sleeve.
 26. A rehabilitated pipe system comprising therehabilitated host pipe of claim 21, wherein the host pipe comprises afirst host pipe and the liner comprises a first liner, the rehabilitatedpipe system further comprising a second host pipe and a second linerextending through the second host pipe and being sealed to the firstliner such that the first and second liners define a standalone fluidflow path having no fluid communication with the existing host pipe. 27.A rehabilitated pipe system as set forth in claim 26 further comprisinga coupler mounted on the coupling section and coupling the first linerto the second liner and sealing the first and second liners to oneanother.
 28. A rehabilitated host pipe comprising: an existing hostpipe; a liner lining an inside surface of the pipe and having aconnecting portion extending out of an end of the pipe; and a tubularreinforcing member positioned generally at the end of the pipe andbonded to the connecting portion of the liner, the reinforcing memberand connecting portion of the liner forming a coupling sectionconfigured to have a coupler mounted thereon for connecting the liner influid communication with another pipe, the reinforcing member providingthe coupling section with resistance against buckling.
 29. Arehabilitated host pipe as set forth in claim 28 further comprisingepoxy positioned between the liner and reinforcing member and bondingthe reinforcing member to the liner.
 30. A rehabilitated host pipe asset forth in claim 29 wherein the epoxy is applied to an inside surfaceof the reinforcing member.
 31. A rehabilitated host pipe as set forth inclaim 30 wherein the reinforcing member comprises glass.
 32. Arehabilitated host pipe as set forth in claim 30 wherein the reinforcingmember comprises resin containing material.
 33. A method forrehabilitating a fluid conveying passage, the method comprising:positioning a liner in the passage so that the liner generally conformsto a perimeter of the passage; curing the liner positioned in thepassage such that the cured liner defines a fluid conveying lumenextending through the passage; and exposing an end portion of the curedliner that was cured within the passage outside of the passage.
 34. Themethod as set forth in claim 33 wherein exposing the end portion of thecured liner comprises removing a structure defining a portion of thepassage.
 35. The method as set forth in claim 34 wherein removing astructure defining a portion of the passage comprises removing a tubularmold from the cured liner.
 36. The method as set forth in claim 35further comprising positioning the tubular mold end to end with a pipesegment of a previously installed pipe system prior to positioning theliner, the tubular mold and pipe segment defining at least a portion ofthe passage.
 37. The method as set forth in claim 33 further comprisingcoupling a coupler to the exposed end portion of the liner to fluidlyconnect the lined passage to another fluid conveying structure.
 38. Themethod as set forth in claim 33 further comprising adhering areinforcing member to the exposed end portion of the liner.
 39. Themethod as set forth in claim 38 further comprising coupling a coupler tothe exposed end portion of the liner to fluidly connect the linedpassage to another fluid conveying structure after adhering thereinforcing member to the exposed end portion section of the liner. 40.The method as set forth in claim 33 further comprising applying a resinto an outside surface of the exposed portion of the liner.
 41. Themethod as set forth in claim 33 further comprising adhering areinforcing member to the exposed portion of the liner.